SM 2

100-00-1 General Information 100-00-1
SECTION 100-00 General Information

VEHICLE APPLICATION:2007.50 Transit
CONTENTS PAGE
DESCRIPTION AND OPERATION

About This Manual.............................................................................................................. 100-00-3
Introduction......................................................................................................................... 100-00-3
Special Tools...................................................................................................................... 100-00-3
Important Safety Instructions.............................................................................................. 100-00-3
Warnings, Cautions and Notes in This Manual.................................................................. 100-00-3
Overview Procedures......................................................................................................... 100-00-3
Trustmark Authoring Standards (TAS) Removal and Installation Procedures.................... 100-00-4
How to Use This Manual.................................................................................................... 100-00-13
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Health and Safety Precautions........................................................................................... 100-00-15
Introduction......................................................................................................................... 100-00-15
Acids and Alkalis................................................................................................................ 100-00-15
Air Bags.............................................................................................................................. 100-00-15
Air Conditioning Refrigerant............................................................................................... 100-00-15
Adhesives and Sealers....................................................................................................... 100-00-16
Antifreeze........................................................................................................................... 100-00-17
Asbestos............................................................................................................................. 100-00-17
Battery Acids...................................................................................................................... 100-00-17
Brake and Clutch Linings and Pads................................................................................... 100-00-17
Brake Fluids (Polyalkylene Glycols)................................................................................... 100-00-17
Brazing............................................................................................................................... 100-00-17
Chemical Materials............................................................................................................. 100-00-17
Chlorofluorocarbons (CFC)................................................................................................ 100-00-18
Clutch Fluids....................................................................................................................... 100-00-18
Clutch Linings and Pads..................................................................................................... 100-00-18
Corrosion Protection Materials........................................................................................... 100-00-18
Cutting................................................................................................................................ 100-00-18
Dewaxing............................................................................................................................ 100-00-19
Dusts.................................................................................................................................. 100-00-19
Electric Shock..................................................................................................................... 100-00-19
Engine Oils......................................................................................................................... 100-00-19
Exhaust Fumes................................................................................................................... 100-00-19
Fibre Insulation................................................................................................................... 100-00-19
Fire..................................................................................................................................... 100-00-19
First Aid.............................................................................................................................. 100-00-20
Fluoroelastomer.................................................................................................................. 100-00-20
Foams - Polyurethane........................................................................................................ 100-00-20
Freon.................................................................................................................................. 100-00-20
Fuels................................................................................................................................... 100-00-20
Gas Cylinders..................................................................................................................... 100-00-21
Gases................................................................................................................................. 100-00-21
Gaskets (Fluoroelastomer)................................................................................................. 100-00-21
General Workshop Tools and Equipment........................................................................... 100-00-21
High Pressure Air, Lubrication and Oil Test Equipment...................................................... 100-00-22
Halon.................................................................................................................................. 100-00-22
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Legal Aspects..................................................................................................................... 100-00-22
Lubricants and Greases..................................................................................................... 100-00-22
Transmission Fluids............................................................................................................ 100-00-22
Noise.................................................................................................................................. 100-00-23
Noise Insulation Materials.................................................................................................. 100-00-23
O-Rings (Fluoroelastomer)................................................................................................. 100-00-23
Paints.................................................................................................................................. 100-00-23
Pressurized Equipment...................................................................................................... 100-00-24
Solder................................................................................................................................. 100-00-24
Solvents.............................................................................................................................. 100-00-24
Sound Insulation................................................................................................................. 100-00-24
Suspended Loads............................................................................................................... 100-00-24
Transmission Brake Bands................................................................................................. 100-00-25
Underseal........................................................................................................................... 100-00-25
Viton.................................................................................................................................... 100-00-25
Welding............................................................................................................................... 100-00-25
Warning Symbols on Vehicles............................................................................................ 100-00-26
White Spirit......................................................................................................................... 100-00-27
Standard Workshop Practices............................................................................................ 100-00-28
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Vehicle in Workshop........................................................................................................... 100-00-28
Alternative Fuel................................................................................................................... 100-00-28
Alternative Fuel — Do's...................................................................................................... 100-00-28
Alternative Fuel — Do Nots................................................................................................ 100-00-28
Towing the Vehicle.............................................................................................................. 100-00-29
Connecting a Slave Battery Using Jumper Cables............................................................ 100-00-29
Component Cleaning.......................................................................................................... 100-00-30
Calibration of Essential Measuring Equipment................................................................... 100-00-30
Solvents, Sealants and Adhesives..................................................................................... 100-00-31
Introduction......................................................................................................................... 100-00-31
Road/Roller Testing............................................................................................................ 100-00-32
Pre-Test Checks................................................................................................................. 100-00-32
Starting the Engine............................................................................................................. 100-00-32
Road or Roller Testing........................................................................................................ 100-00-32
Brake Testing...................................................................................................................... 100-00-33
Battery and Battery Charging Health and Safety Precautions............................................ 100-00-34
Engine Cooling System Health and Safety Precautions..................................................... 100-00-35
Petrol Fuel System Health and Safety Precautions............................................................ 100-00-36
Diesel Fuel System Health and Safety Precautions........................................................... 100-00-37
Air Conditioning (A/C) System Health and Safety Precautions.......................................... 100-00-38
Supplemental Restraint System (SRS) Health and Safety Precautions............................. 100-00-39
Brake System Health and Safety Precautions.................................................................... 100-00-40

About This Manual

Introduction CAUTION:Cautions are used to indicate
that failure to follow a procedure correctly
This manual has been written in a format that is may result in damage to the vehicle or
designed to meet the needs of technicians equipment being used.
worldwide. The objective is to use common formats
and include similar content in each manual. NOTE:Notes are used to provide additional
essential information required to carry out a
This manual provides general descriptions for complete and satisfactory repair.
accomplishing diagnosis and testing, service and
repair work with tested, effective techniques. As you read through this manual, you will come
Following them will help assure reliability. across WARNINGS, CAUTIONS and NOTES.
A warning, caution or note is placed at the
beginning of a series of steps if it applies to multiple
Special Tools steps. If the warning, caution or note only applies
to one step, it is placed at the beginning of the
The special tool(s) table provided at the beginning specific step (after the step number).
of each procedure shows all special tools required
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to carry out a repair. Where possible, illustrations
are provided to assist in identifying the special tool Overview Procedures
required.
Overview procedures contain an exploded view
illustration(s). The numbered sequence within the
Important Safety Instructions illustration(s) indicate the order to be followed when
removing/disassembling or when
Appropriate service methods and correct repair installing/assembling a component. Additional
procedures are essential for the safe, reliable information, symbol(s) or a torque figure, may also
operation of all motor vehicles as well as the be shown alongside the component.
personal safety of the individual carrying out the
work. There are ten symbols used to give additional
information when removing/disassembling or when
This manual cannot possibly anticipate all such installing/assembling a component.
variations and provide advice or cautions as to
each. Anyone who departs from the instructions
provided in this manual must first establish that he
1 2 3 4 5 6 7 8 9 10
compromises neither his personal safety nor the
vehicle integrity by his choice of methods, tools or
components.
Warnings, Cautions and Notes in This

Manual
WARNING:Warnings are used to indicate
that failure to follow a procedure correctly TIE42918
may result in personal injury.
Item Designation Description

1 Special tool A special tool is required for this component. There will also
be a removal or installation symbol alongside the special
tool symbol.
2 Install new component Discard the old component and install a new component.
3 Inspect Check the component for damage.
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Item Designation Description

4 Apply sealant Apply sealant to the component as specified in the mate-
rials table.
5 Apply petroleum jelly Apply petroleum jelly to the component as specified in the
materials table.
6 Apply oil Apply oil to the component as specified in the materials table.
7 Apply fluid Apply fluid to the component as specified in the materials
table.
8 Apply grease Apply grease to the component as specified in the mate-rials
table.
9 Removal or Disassembly Go to the removal or disassembly detail for additional
detail information to remove or disassemble a component
10 Installation or Assembly Go to the installation or assembly detail for additional
detail information to install or assemble a component
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Special Tools and Torque Figures NOTE:Removal steps in this procedure may
contain installation details.
Any requirement for special tools will picture the
tool, showing it in use and with its tool number Items such as O-ring seals, gaskets, seals,
shown. Torque settings will be given at the relevant self-locking nuts and bolts are to be discarded and
point in the procedure. new components installed unless otherwise stated
within the procedure. Coated nuts or bolts are to
be reused, unless damaged or otherwise stated
within the procedure.
59 Nm 23-045
Specification procedures will contain all technical
data that are not part of a repair procedure.
TAS Graphics
Colors used in the graphic are as follows:
• Blue - Indicates the target item, item to be
removed/installed or disassembled/assembled
TIA2301151 • Green and Brown - Indicates a secondary item
that needs to be detached, removed/installed
or disassembled/assembled prior to the target
Trustmark Authoring Standards (TAS) item
Removal and Installation Procedures • Magenta - Indicates electrical connectors and
fasteners such as nuts, bolts, clamps or clips
NOTE:TAS style procedures can be identified by • Pale Blue - is for the special tool(s) and general
steps that have no accompanying step text and equipment
the magenta color of the electrical connectors and
fasteners such as nuts, bolts, clamps or clips. There may be multiple steps assigned to one
illustration.
A TAS removal and installation procedure uses a
sequence of color illustrations to indicate the order Numbered pointers are used to indicate the number
to be followed when removing/disassembling or of electrical connectors and fasteners such as nuts,
installing/assembling a component. bolts, clamps or clips.
Many of the TAS procedures will have the Items in the illustration can be transparent or use
installation information within the removal steps. cutouts to show hidden detail(s).
These procedures will have the following note at
the beginning of the procedure:
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2 303-378 205-072
4
1
3 x3
E63828 E60043
TAS Symbols
Symbols are used inside the graphics and in the
text area to enhance the information display. The
following paragraphs describe the various types
and categories of symbols.
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Prohibition symbols advise on prohibited actions
to either avoid damage or health and safety related
risks.
E85026
Health and Safety symbols recommend the use of

particular protection equipment to avoid or at least
reduce the risk or severity of possible injuries.
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E85027
Warning symbols are used to indicate potential

risks resulting from a certain component or area.
E85028
2007.50 Transit 11/2006 G935689en

Instruction symbols are used to apply sealer, component.
lubricant, weight, tape or cleaning detergent to a
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E84834
Location symbols are used to show the location of

a component or system within the vehicle.
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E84835
Gearshift lever or selector lever position symbols

are used to show which gearshift lever or selector
lever position is to be set.
2007.50 Transit 11/2006 G935689en

308-640
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E84836
Pointer symbols are used to draw the attention to located inside the circle. Numbers inside circles
components and give special instructions such as are also used to allocate special information such
a required sequence or number of components. as tightening torques or chemicals to a particular
The number of components is reflected by the component.
value inside the luty arrow. A sequence number is
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3
2
2
x12
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E84837
Movement arrows are used to show three

dimensional or rotational movements. These
movements can include specific values inside the
symbol if required.
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E84839
The following graphic illustrates a set of symbols

that are used to provide detailed information on
where to apply a material.
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E84840
Measurement symbols provide detailed information

on where to carry out a specific measurement.
These symbols can include specific values if
required.
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2
E84841
Special Tools and Torque Figure(s) If components need to be removed or

disassembled in sequence, the sequence will be
Special tools will be shown with the tool number
identified numerically in a graphic and the
in the illustration. The special tool number(s),
corresponding text will be numbered accordingly.
general equipment, material(s) and torque figure(s)
used for the procedure step will be shown in the All left and right-hand references to the vehicle are
text column. taken from a position sitting in the driver seat
looking forward.
How to Use This Manual All left and right-hand references to the engine are
taken from a position at the flywheel looking
This manual covers diagnosis and testing, service towards the front camshaft pulley.
and repair procedures. Where appropriate, instructions will be given for
This manual is structured into groups and sections, the use of the diagnostic tool.
with specific system sections collected together
Inspection and Verification
under their relevant group.
A group covers a specific portion of the vehicle. Visual Inspection Charts, Symptom Charts and
The manual is divided into five groups, General other information charts (such as diagnostic
Information, Chassis, Powertrain, Electrical and routines) or supplement test procedures with
Body and Paint. The number of the group is the technical specifications will navigate the user to a
first number of a section number. specific test procedure.
Pages at the start of the manual list all sections Symptom Chart
available. Each section has a contents list detailing The symptom chart indicates symptoms, sources
Specifications, Description and Operation, and actions to address a condition.
Diagnosis and Testing, In Vehicle Repairs,
Disassembly and Assembly, Removal and
Installation.
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Pinpoint Tests
For electrical systems, pinpoint test steps are used
to identify the source of a concern in a logical,
step-by-step manner. pinpoint tests have two
columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is used exclusively for
graphics and icons (with or without captions) and
the DETAILS/RESULTS/ACTIONS column
provides direction to another test step or specific
corrective actions.
The boxed numbers indicate the order in which the
described action is to be performed.
Component Tests
A component test is used when a component is
tested in multiple pinpoint tests, or if a procedure
is too complicated to be formatted within a single
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page of the pinpoint test.
Graphics
Test graphics show the measurement or test to be
performed in a test step.
A representative tester graphic is used for
voltmeters and ohmmeters.
If multiple measurements are made in a single
graphic, the test leads are drawn with a solid line
until the test lead splits to indicate the multiple
measurements, at which point dashed lines are
used.
Breakout box-type testers are represented by a
double circle test pin. Test pins are labeled with
the pin number.
2007.50 Transit 11/2006 G935689en

Health and Safety Precautions

Introduction inflator as this will lead to the risk of exposure to
Sodium Azide. If a gas generator is ruptured, full
Many of the procedures associated with vehicle protective clothing should be worn when dealing
maintenance and repair involve physical hazards with the spillage.
or other risks to health. This subsection lists, After normal deployment, gloves and safety
alphabetically, some of these hazardous operations goggles must be worn during the handling process.
and the materials and equipment associated with
them. Precautions necessary to avoid these Deployed air bags should be disposed of in a
hazards are identified. plastic bag in accordance with local regulations at
an approved chemical waste site.
The list is not exhaustive and all operations and
procedures, and the handling of materials, should Following any direct contact with gas generant.
be carried out with health and safety in mind. – wash affected areas thoroughly with water.
Before using any product the Materials Safety Data – seek medical assistance if necessary.
Sheet supplied by the manufacturer or supplier
Air Bags - Do's
should be consulted.
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– Do store modules in an upright position.
– Do keep modules dry.
Acids and Alkalis
– Do carry modules with the cover side pointing
See also Battery Acids. away from the body.
– Do place modules with their cover side upwards.
For example caustic soda, sulphuric acid.
– Do carefully inspect modules for damage.
Used in batteries and cleaning materials.
– Do stand to one side when connecting modules.
Irritant and corrosive to the skin, eyes, nose and – Do make sure all test equipment is properly
throat. Cause burns. Can destroy ordinary calibrated and maintained.
protective clothing.
– Do wash hands after handling deployed air
Avoid splashes to the skin, eyes and clothing. Wear bags.
suitable protective impervious apron, gloves and
Air Bags - Do Nots
goggles. Do not breath mists.
– Do not store highly flammable material together
Make sure access to eye wash bottles, shower and
with modules or gas generators.
soap are readily available for splashing accidents.
– Do not store gas generators at temperatures
Display Eye Hazard sign. exceeding 80°C.
– Do not store modules upside down.
Air Bags – Do not attempt to open a gas generator housing.
– Do not expose gas generators to open flame or
See also Fire, Chemical Materials. sources of heat.
Highly flammable, explosive – observe No Smoking – Do not place anything on top of a module cover.
policy. – Do not use damaged modules.
Used as a safety restraint system mounted in the – Do not touch a fired module or gas generator
steering wheel and passenger side of the for at least 10 minutes.
instrument panel. – Do not use any electrical probes on the wiring
The inflator contains a high-energetic propellant circuit.
which, when ignited, produces a VERY HOT GAS
(2500°C).
Air Conditioning Refrigerant
The gas generant used in air bags is Sodium Azide.
This material is hermetically sealed in the module See also Chlorofluorocarbon, Chemical Materials
and is completely consumed during deployment.
No attempt should be made to open an air bag Highly flammable, combustible – observe No
Smoking policy.
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Skin contact may result in frostbite. Hot Melt Adhesives
Instructions given by the manufacturer must be
In the solid state, they are safe. In the molten state
followed. Avoid naked lights, wear suitable
they may cause burns and health hazards may
protective gloves and goggles.
arise from the inhalation of toxic fumes.
If refrigerant comes into contact with the skin or
Use appropriate protective clothing and a
eyes, immediately rinse the affected areas with
thermostatically controlled heater with a thermal
water. Eyes should also be rinsed with an
cut-out and adequate extraction.
appropriate irrigation solution and should not be
rubbed. SEEK MEDICAL ASSISTANCE IF
NECESSARY.
Resin-based Adhesives/Sealers, for
example Epoxide and Formaldehyde
Air Conditioning Refrigerant - Do Nots Resin-based
Mixing should be carried out in well ventilated

– Do not expose refrigerant bottles to sunlight or
areas, as harmful or toxic volatile chemicals may
heat.
be released.
– Do not stand refrigerant bottles upright; when
filling, hold them with the valve downwards. Skin contact with uncured resins and hardeners
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can result in irritation, dermatitis, and absorption
– Do not expose refrigerant bottles to frost.
of toxic or harmful chemicals through the skin.
– Do not drop refrigerant bottles. Splashes can damage the eyes.
– Do not vent refrigerant to atmosphere under any
Provide adequate ventilation and avoid skin and
circumstance.
eye contact.
– Do not mix refrigerants, for example R12 (Freon)
and R134a.
Anaerobic, Cyanoacrylate (super-glues)
Adhesives and Sealers and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin

See also Fire, Chemical Materials.
and respiratory tract. Some are eye irritants.
Highly flammable, flammable, combustible –
Skin and eye contact should be avoided and the
observe No Smoking policy.
manufacturers instructions followed.
Generally should be stored in No Smoking areas.
Cyanoacrylate adhesives (super-glues) MUST NOT
Cleanliness and tidiness in use should be
contact the skin or eyes. If skin or eye tissue is
observed, for example disposable paper covering
bonded, cover with a clean moist pad and SEEK
benches; should be dispensed from applicators
IMMEDIATE MEDICAL ATTENTION. Do not
where possible; containers, including secondary
attempt to pull tissue apart. Use in well ventilated
containers, should be labeled appropriately.
areas as vapors can cause irritation to the nose
and eyes.
Solvent-based Adhesives/Sealers - See For two-pack systems see Resin-based and
Solvents Isocyanate Adhesives/Sealers.
Follow manufacturers instructions.

Isocyanate (Polyurethane)
Adhesives/Sealers
Water-based Adhesives/Sealers
See also Resin-based Adhesives.
Those based on polymer emulsions and rubber
Individuals suffering from asthma or respiratory
latexes may contain small amounts of volatile toxic
allergies should not work with or near these
and harmful chemicals. Skin and eye contact
materials as sensitivity reactions can occur.
should be avoided and adequate ventilation
provided during use. Over exposure is irritating to the eyes and
respiratory system. Excessive concentrations may
produce effects on the nervous system including
2007.50 Transit 11/2006 G17372en

drowsiness. In extreme cases, loss of Asbestos dust waste should be dampened, placed
consciousness may result. Long term exposure to in a sealed container and marked for safe disposal.
vapor concentrations may result in adverse health If any cutting or drilling is attempted on materials
effects. containing asbestos the item should be dampened
Prolonged contact with the skin may have a and only hand tools or low speed power tools used.
defatting effect which may lead to skin irritation
and in some cases, dermatitis. Battery Acids
Splashes entering the eye will cause discomfort
and possible damage. See also Acids and Alkalis.
Any spraying should preferably be carried out in Gases released during charging are explosive.
exhaust ventilated booths, removing vapors and Never use naked flames or allow sparks near
spray droplets from the breathing zone. charging or recently charged batteries.
Wear appropriate gloves, eye and respiratory Make sure there is adequate ventilation.
protection.
Brake and Clutch Linings and Pads
Antifreeze
See Asbestos.
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See also Fire, Solvents.
For example isopropanol, ethylene glycol, Brake Fluids (Polyalkylene Glycols)
methanol.
See also Fire.
Highly flammable, flammable, combustible.
Splashes to the skin and eyes are slightly irritating.
Used in vehicle coolant systems, brake air pressure
Avoid skin and eye contact as far as possible.
systems, screenwash solutions.
Inhalation vapor hazards do not arise at ambient
Vapors may be given off from coolant antifreeze temperatures because of the very low vapor
(glycol) when heated. Avoid breathing these pressure.
vapors.
Antifreeze may be absorbed through the skin in Brazing
toxic or harmful quantities. Antifreeze, if swallowed,
can be fatal and MEDICAL ATTENTION SHOULD See Welding.
BE SOUGHT IMMEDIATELY.
These products must not be used in any cooling
Chemical Materials
or industrial water system that is connected or
linked to general, food preparation or drinking water
See also Legal Aspects.
supplies.
Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids,
Asbestos antifreeze, brake fluids, fuels, oils and grease
should always be used with caution and stored and
See also Warning Symbols on Vehicles at the end handled with care. They may be toxic, harmful,
of this subsection. corrosive, irritant or highly flammable and give rise
Breathing asbestos dust may cause lung damage to hazardous fumes and dusts.
or, in some cases, cancer. The effects of excessive exposure to chemicals
Used in brake and clutch linings, transmission may be immediate or delayed; briefly experienced
brake bands and gaskets. or permanent; cumulative; superficial; life
threatening; or may reduce life expectancy.
The use of drum cleaning units, vacuum cleaning
or damp wiping is preferred.
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Chemical Materials - Do's – Do not clean hands or clothing with chemicals.
Chemicals, particularly solvents and fuels, will
– Do carefully read and observe hazard and dry the skin and may cause irritation leading to
precaution warnings given on material dermatitis or be absorbed through the skin in
containers (labels) and in any accompanying toxic or harmful quantities.
leaflets, posters or other instructions. Material – Do not use emptied containers for other
health and safety data sheets can be obtained materials except when they have been cleaned
from manufacturers. under supervised conditions.
– Do remove chemical materials from the skin – Do not sniff or smell chemical materials. Brief
and clothing as soon as practicable after soiling. exposure to high concentrations of fumes can
Change heavily soiled clothing and have it be toxic or harmful.
cleaned.
– Do organize work practices and protective
clothing to avoid soiling of the skin and eyes; Chlorofluorocarbons (CFC)
breathing vapors, aerosols, dusts or fumes;
inadequate container labeling; fire and explosion There is concern in the scientific community that
hazards. CFCs and Halons are depleting the upper ozone
layer which filters out harmful ultraviolet radiation.
– Do wash before job breaks, before eating,
Decreased filtration of ultraviolet radiation may
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smoking, drinking or using toilet facilities when
result in increases in skin cancer, cataracts and
handling chemical materials.
immune system suppression in humans, as well
– Do keep work areas clean, uncluttered and free as decreased productivity of crops and aquatic
of spills. systems.
– Do store chemical materials according to CFCs are used primarily as refrigerants in vehicle
national and local regulations. air conditioning systems and as aerosol
– Do keep chemical materials out of the reach of propellants. Halons are used as fire extinguishants.
children.
Clutch Fluids
Chemical Materials - Do Nots
See Brake fluids.
– Do not mix chemical materials except under the
manufacturers instructions; some chemicals can
form other toxic or harmful chemicals, give off Clutch Linings and Pads
toxic or harmful fumes or become explosive
when mixed together. See Asbestos.
– Do not spray chemical materials, particularly
those based on solvents, in confined spaces, Corrosion Protection Materials
for example when people are inside a vehicle.
– Do not apply heat or flame to chemical materials See also Solvents, Fire.
except under the manufacturers instructions. Highly flammable, flammable – observe No
Some are highly flammable and some may Smoking policy.
release toxic or harmful fumes.
These materials are varied and the manufacturers
– Do not leave containers open. Fumes given off instructions must be followed. They may contain
can build up to toxic, harmful or explosive solvents, resins or petroleum products. Skin and
concentrations. Some fumes are heavier than eye contact should be avoided. They should only
air and will accumulate in confined areas such be sprayed in conditions of adequate ventilation
as pits. and not in confined spaces.
– Do not transfer chemical materials to unlabelled
containers.
Cutting
See Welding.
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Dewaxing Engine Oils
See Solvents and Fuels (Kerosene). See Lubricants and Grease.
Dusts Exhaust Fumes

Powder, dusts or clouds may be irritant, harmful These contain asphyxiating, harmful and toxic
or toxic. Avoid breathing dusts from powdery chemicals and particles such as carbon oxides,
chemical materials or those arising from dry nitrogen oxides, aldehydes, lead and aromatic
abrasion operations. Wear respiratory protection hydrocarbons. Engines should be run only under
if ventilation is inadequate. conditions of adequate exhaust extraction or
Fine dusts of combustible material can present an general ventilation and not in confined spaces.
explosion hazard. Avoid explosive limits and
sources of ignition.
Gasoline (petrol) engine
Electric Shock There may not be adequate warning of odor or of

irritation before toxic or harmful effects arise. These
may be immediate or delayed.
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Electric shock can result from the use of faulty
electrical equipment or from the misuse of
equipment in good condition.
Diesel engine
Make sure that electrical equipment is maintained
in good condition and frequently tested. Faulty Soot, discomfort and irritation usually give
equipment should be labeled and preferably adequate warning of hazardous fume
removed from the workstation. concentrations.
Make sure that flexes, cables, plugs and sockets
are not frayed, kinked, cut, cracked or otherwise
damaged.
Fibre Insulation
Make sure that electrical equipment and flexes do See also Dusts.
not come into contact with water.
Used in noise and sound insulation.
Make sure that electrical equipment is protected
The fibrous nature of surfaces and cut edges can
by the correct rated fuse.
cause skin irritation. This is usually a physical and
Never misuse electrical equipment and never use not a chemical effect.
equipment that is in any way faulty. The results
Precautions should be taken to avoid excessive
could be fatal.
skin contact through careful organization of work
Make sure that the cables of mobile electrical practices and the use of gloves.
equipment cannot get trapped and damaged, such
as in a vehicle hoist.
Fire
Make sure that the designated electrical workers
are trained in basic First Aid. See also Welding, Foams, Legal Aspects.
In cases of electrocution: Many of the materials found on or associated with
– switch off the power supply before approaching the repair of vehicles are highly flammable. Some
the victim. give off toxic or harmful fumes if burnt.
– if this is not possible push or drag the victim Observe strict fire safety when storing and handling
from the source of electricity using dry flammable materials or solvents, particularly near
non-conductive material. electrical equipment or welding processes.
– commence resuscitation if trained to do so. Make sure, before using electrical or welding
– SUMMON MEDICAL ASSISTANCE. equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when
using welding or heating equipment.
2007.50 Transit 11/2006 G17372en

First Aid foams should be conducted with extraction
ventilation. See also the vehicle Body Repair
Apart from meeting any legal requirements it is Manual.
desirable for someone in the workshop to be
trained in First Aid procedures.
Freon
Splashes in the eye should be flushed carefully
with clean water for at least ten minutes. See Air Conditioning Refrigerant.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place Fuels
affected area in cool to cold water.
See also, Fire, Legal Aspects, Chemicals and
Individuals affected by inhalation of gases and
Solvents.
fumes should be removed to fresh air immediately.
If effects persist, consult a doctor. Avoid skin contact with fuel where possible. Should
contact occur, wash the affected skin with soap
If liquids are swallowed inadvertently, consult a
and water.
doctor giving him the information on the container
or label. Do not induce vomiting unless this action
is indicated on the label. Gasoline (Petrol)
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Fluoroelastomer Highly flammable - observe No Smoking policy.
Swallowing can result in mouth and throat irritation
See Viton. and absorption from the stomach can result in
drowsiness and unconsciousness. Small amounts
can be fatal to children. Aspiration of liquid into the
Foams - Polyurethane
lungs, through vomiting, is a very serious hazard.
See also Fire. Gasoline dries the skin and can cause irritation
and dermatitis on prolonged or repeated contact.
Used in sound and noise insulation. Cured foams
Liquid in the eye causes severe smarting.
used in seat and trim cushioning.
Motor gasoline may contain appreciable quantities
Follow manufacturers instructions.
of benzene, which is toxic upon inhalation, and the
Unreacted components are irritating and may be concentration of gasoline vapors must be kept very
harmful to the skin and eyes. Wear gloves and low. High concentrations will cause eye, nose and
goggles. throat irritation, nausea, headache, depression and
Individuals with chronic respiratory diseases, symptoms of drunkenness. Very high
asthma, bronchial medical problems, or histories concentrations will result in rapid loss of
of allergic diseases should not work in or near consciousness.
uncured materials. Make sure there is adequate ventilation when
The components, vapors or spray mists can cause handling and using gasoline. Great care must be
direct irritation, sensitivity reactions and may be taken to avoid the serious consequences of
toxic or harmful. inhalation in the event of vapor build up arising
from spillages in confined spaces.
Vapors and spray mists must not be inhaled. These
materials must be applied with adequate ventilation Special precautions apply to cleaning and
and respiratory protection. Do not remove the maintenance operations on gasoline storage tanks.
respirator immediately after spraying; wait until the Gasoline should not be used as a cleaning agent.
vapors/mists have cleared. It must not be siphoned by mouth. See First Aid.
Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical Gas-oil (Diesel Fuel)
equipment during foaming operations and until
Combustible.
vapors/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
2007.50 Transit 11/2006 G17372en

Gross or prolonged skin contact with high boiling If the fuel tank is to be removed for service or repair
point gas oils may also cause serious skin the fuel must be evacuated using dedicated
disorders including skin cancer. equipment and following the specified procedures.
Kerosene (Paraffin) Gas Cylinders
Used also as heating fuel, solvent and cleaning See also Fire.
agent. Gases such as oxygen, acetylene, argon and
Flammable - observe No Smoking policy. propane are normally stored in cylinders at
pressures of up to 138 bar (2000 psi) and great
Irritation of the mouth and throat may result from care should be taken in handling these cylinders
swallowing. The main hazard from swallowing to avoid mechanical damage to them or to the valve
arises if liquid aspiration into the lungs occurs. gear attached. The contents of each cylinder
Liquid contact dries the skin and can cause should be clearly identified by appropriate
irritation or dermatitis. Splashes in the eye may be markings.
slightly irritating. Cylinders should be stored in well-ventilated
In normal circumstances the low volatility does not enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases, for example acetylene
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give rise to harmful vapors. Exposure to mists and
vapors from kerosene at elevated temperature and propane, should not be stored in close
should be avoided (mists may arise in dewaxing). proximity to oxygen cylinders.
Avoid skin and eye contact and make sure there Care should be exercised to prevent leaks from
is adequate ventilation. gas cylinders and lines, and to avoid sources of
ignition.
Alternative Fuel Only trained personnel should undertake work
involving gas cylinders.
Highly flammable. Observe ``NO SMOKING" signs.
Make sure there is adequate ventilation when Gases
working on alternative fuelled vehicles. Great care
must be taken to avoid the serious consequences See Gas Cylinders.
of inhalation in the event of vapor build up in
confined spaces.
Gaskets (Fluoroelastomer)
Inhalation in high concentrations may cause
dizziness, headache, nausea and loss of See Viton.
co-ordination. Very high concentrations may result
in loss of consciousness.
General Workshop Tools and
Contact with liquefied petroleum gas (LPG) or Equipment
compressed natural gas (CNG) to the skin may
cause cold burns and frost bite. It is essential that all tools and equipment are
Long sleeved cotton overalls, steel toe capped maintained in good condition and that the correct
safety boots and rubber neoprene gloves should safety equipment is used where required.
be worn during removal and installation of Never use tools or equipment for any purpose other
LPG/CNG fuel system components. than that for which they were designed. Never
LPG/CNG fuel leaks could cause a fire and be a overload equipment such as hoists, jacks, axle and
hazard to health that can lead to personal injury, chassis stands or lifting slings. Damage caused by
illness or even death. overloading is not always immediately apparent
and may result in a fatal failure the next time that
If a leak is detected, under no circumstances
the equipment is used.
attempt to seal the leak by tightening the
union/connection until the fuel in the system or
component is depressurized. Once tightened the
system should be checked for integrity following
the specified procedures.
2007.50 Transit 11/2006 G17372en

Do not use damaged or defective tools or Transmission Fluids
equipment, particularly high-speed equipment such
as grinding wheels. A damaged grinding wheel can
disintegrate without warning and cause serious Safety instructions
injury.
Certain Transmission and Power Steering fluids
Wear suitable eye protection when using grinding,
supplied to Ford may contain additives which have
chiseling or sand blasting equipment.
the potential to cause skin disease (dermatitis) to
Wear a suitable breathing mask when using exposed persons. The dermatitis may be irritant
abrasive blasting equipment, working with or allergic in nature. Risks are higher where
asbestos-based materials or using spraying prolonged or repeated skin contact with a fluid may
equipment. occur. These fluids are used for vehicle initial fill
Make sure there is adequate ventilation to control and service purposes. This sub-section is to:
dusts, mists and fumes. • Inform Service personnel who may come into
contact with these vehicle fluids (hazard
communication).
High Pressure Air, Lubrication and Oil
Test Equipment • Summarise appropriate workplace control
measures and personal protective equipment
requirements.
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See also Lubricants and Greases.
• Draw attention to the existence of Material
Always keep high-pressure equipment in good Safety Datasheets (MSDS's) for the fluids
condition, and regularly maintained, particularly at (available from Ford Customer Service Division).
joints and unions. These MSDS's contain detailed information on
Never direct a high-pressure nozzle, for example hazards and appropriate controls.
diesel injector, at the skin as the fluid may
penetrate to the underlying tissue, and cause
serious injury. Control measures
Workplace risk assessments made under national

Halon chemical control regulations should identify
operations involving the fluids as potentially
See CFCs. hazardous and specify workplace control and
worker awareness measures. In such
Legal Aspects circumstances, the relevant Material Safety
Datasheet (see the details specified below) which
There are many laws and regulations relating to specifies hazards and control measures in detail
health and safety in the use and disposal of should be made available for guidance.
materials and equipment in a workshop. Avoid unprotected skin contact with the fluids, and
For a safe working environment and to avoid in particular, avoid prolonged or repeated skin
environmental pollution, workshops should be contact. Work practices should be organised so as
familiar, in detail, with the many health and safety to minimise the potential for skin contact. This may
laws and regulations within their country, published include the use of drip trays, absorbents, correct
by both national and local authorities. fluid handling equipment (funnels etc), and
workplace housekeeping measures such as the
cleaning of contaminated surfaces.
Lubricants and Greases Personnel engaged in operations where skin
contact could occur (such as fluid draining or filling)
Avoid all prolonged and repeated contact with should wear impervious gloves made from nitrile
mineral oils. All lubricants and greases may be rubber, certified to a chemical protection standard,
irritating to the eyes and skin. e.g. Europe Standard EN374. This glove type is
widely available from reputable suppliers of gloves
for chemical protection [including the manufacturers
Ansell-Admont (Solvex Range), North Safety
products (North Nitrile Latex Gloves range), and
2007.50 Transit 11/2006 G17372en

Marigold Industrial (Blue Nitrile range)]. If gloves Do not employ used engine oils as lubricants or
become torn or contaminated on the inside they for any application where appreciable skin contact
should be replaced. Eye protection with safety is likely to occur.
glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more
extensive exposure is possible. Use of skin barrier Environmental Precautions
creams suitable for work with mineral oil products
may offer some supplementary protection, but such Burning used engine oil in small space heaters or
barrier creams should not be used in place of boilers can be recommended only for units of
protective clothing. approved design. If in doubt check with the
appropriate local authority and manufacturer of
If accidental skin contact occurs with the fluids,
approved appliances.
wash the area thoroughly with soap or skin
cleanser and water. Dispose of used oil and used oil filters through
authorized waste disposal contractors or licensed
Accidental eye contact should be dealt with as per
waste disposal sites, or to the waste oil reclamation
normal first aid practices, by flushing the eyes with
trade. If in doubt, contact the relevant local
an eye wash or clean cool water for 10 minutes,
authority for advice on disposal facilities.
after which medical attention should be obtained.
It is illegal to pour used oil on to the ground, down
Remove and launder clothing which becomes
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sewers or drains, or into watercourses.
contaminated with the fluids. Do not place rags
contaminated with fluid in clothing pockets.
Wash thoroughly after completing operations where Noise
skin exposure may have occurred.
Some operations may produce high noise levels,
It is important that personnel do not smoke, eat or which could, in time, damage hearing. In these
drink whilst handling the fluids or affected cases, suitable ear protection must be worn.
transmissions. These measures are designed to
limit the risk from accidental ingestion.
Noise Insulation Materials
Label any decanted fluid properly/use an equivalent
label to that on original product containers. See Foams, Fibre Insulation.
Clean up any spills promptly using an inert
absorbent and wash down contaminated surfaces
with detergent and water. O-Rings (Fluoroelastomer)
Dispose of any waste fluids safely as hazardous See Viton.
waste.
Paints
Safety Data Sheets
See also Solvents, Chemical Materials.
Safety Data Sheets, which detail specific material Highly flammable, flammable - observe No
handling instructions and precautions are available Smoking policy
from the respective national sales company, and
via internet www.msds.ford.com.
One Pack
Used Engine Oil Can contain harmful or toxic pigments, driers and
other components as well as solvents. Spraying
Prolonged and repeated contact with mineral oil should be carried out only with adequate
will result in the removal of natural fats from the ventilation.
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants, which may cause skin
cancer. Adequate means of skin protection and
washing facilities must be provided.
2007.50 Transit 11/2006 G17372en

Two Pack Used in cleaning and dewaxing materials, paints,
plastics, resins and thinners.
Can also contain harmful and toxic unreacted
Some may be highly flammable or flammable.
resins and resin hardening agents. The
manufacturers instructions should be followed. See Skin contact will degrease the skin and may result
also Resin-based Adhesives and Isocyanate in irritation and dermatitis following repeated or
Adhesives and Sealers under Adhesives and prolonged contact. Some can be absorbed through
Sealers. the skin in toxic or harmful quantities.
Spraying should preferably be carried out in Splashes in the eye may cause severe irritation
exhausted ventilated booths removing vapor and and could lead to loss of vision.
spray mists from the breathing zone. Individuals Brief exposure of high concentrations of vapors or
working in booths should wear appropriate mists will cause eye and throat irritation,
respiratory protection. Those doing small-scale drowsiness, dizziness, headaches and, in the worst
repair work in the open workshop should wear circumstances, unconsciousness.
air-fed respirators.
Repeated or prolonged exposure to excessive but
lower concentrations of vapors or mists, for which
Pressurized Equipment there might not be adequate warning indications,
can cause more serious toxic or harmful effects.
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See High Pressure Air, Lubrication and Oil Test
Equipment. Aspiration into the lungs, for example through
vomiting, is the most serious consequence of
swallowing.
Solder Avoid splashes to the skin, eyes and clothing. Wear
protective gloves, goggles and clothing if
Solders are mixtures of metals such that the necessary.
melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder Make sure there is good ventilation when in use,
application does not normally give rise to toxic lead avoid breathing fumes, vapors and spray mists and
fumes, provided a gas/air flame is used. keep containers tightly sealed. Do not use in
Oxy-acetylene flames should not be used, as they confined spaces.
are much hotter and will cause lead fumes to be When spraying materials containing solvents, for
produced. example paints, adhesive, coatings, use extraction
Some fumes may be produced by the application ventilation or personal respiratory protection in the
of any flame to surfaces coated with grease, and absence of adequate general ventilation.
inhalation of these should be avoided. Do not apply heat or flame except under specific
Removal of excess solder should be undertaken and detailed manufacturers instructions.
with care, to make sure that fine lead dust is not
produced, which can give toxic effects if inhaled.
Sound Insulation
Respiratory protection may be necessary.
Solder spillage and filings should be collected and See Fibre Insulation, Foams.
removed promptly to prevent general air
contamination by lead.
Suspended Loads
High standards of personal hygiene are necessary
in order to avoid ingestion of lead or inhalation of CAUTION:Never improvise lifting tackle.
solder dust from clothing.
There is always a danger when loads are lifted or
suspended. Never work under an unsupported,
Solvents suspended or raised load, for example a
suspended engine.
See also Chemical Materials, Fuels (Kerosene),
Fire. Always make sure that lifting equipment such as
jacks, hoists, axle stands and slings are adequate
For example acetone, white spirit, toluene, xylene,
and suitable for the job, in good condition and
trichloroethane.
regularly maintained.
2007.50 Transit 11/2006 G17372en

Transmission Brake Bands Welding
See Asbestos. See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding
Underseal (Spot Welding), Arc Welding and Gas Welding.
See Corrosion Protection.

Resistance Welding
Viton This process may cause particles of molten metal
to be emitted at a high velocity, and the eyes and
In common with many other manufacturers skin must be protected.
vehicles, some components have O-rings, seals
or gaskets, which contain a material known as
`Viton'. Arc Welding
Viton is a fluoroelastomer, that is a synthetic rubber
This process emits a high level of ultra-violet
type material, which contains Fluorine. It is
radiation, which may cause arc-eye, and skin burns
commonly used for O-rings, gaskets and seals of
to the operator and to other persons nearby.
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all types. Although Viton is the most well known
Gas-shielded welding processes are particularly
fluoroelastomer, there are others, including Fluorel
hazardous in this respect. Personal protection must
and Tecmoflon.
be worn, and screens used to shield other people.
When used under design conditions
CONTACT LENS WEARERS ARE ADVISED TO
fluoroelastomers are perfectly safe. If, however,
REVERT TO ORDINARY SPECTACLES WHEN
they are exposed to temperatures in excess of
ARC WELDING as the arc spectrum is believed to
400°C, the material will not burn, but will
emit microwaves which dry out the fluid between
decompose, and one of the products formed is
the lens and the eye. This may result in blindness
hydrofluoric acid.
when the lens is removed from the eye.
This acid is extremely corrosive and may be
Metal spatter will also occur, and appropriate eye
absorbed directly, through contact, into the general
and skin protection is necessary.
body system.
The heat of the welding arc will produce fumes and
O-rings, seals or gaskets which have been exposed
gases from the metals being welded, the rods and
to very high temperatures will appear charred or
from any applied coatings or contamination on the
as a black sticky substance.
surfaces being worked on. These gases and fumes
DO NOT; under any circumstances touch them or may be toxic and inhalation of these should be
the attached components. avoided. The use of extraction ventilation to remove
Enquiries should be made to determine whether the fumes from the working area may be necessary
Viton or any other fluoroelastomer has been used particularly in cases where the general ventilation
in the affected O-ring, seal or gasket. If they are of is poor, or where considerable welding work is
natural rubber or nitrile there is no hazard. If in anticipated. In extreme cases or confined spaces
doubt, be cautious, as the material may be Viton where adequate ventilation cannot be provided,
or any fluoroelastomer. air-fed respirators may be necessary.
If Viton or any other fluoroelastomers have been

used, the affected area should be decontaminated Gas Welding (and Cutting)
before the commencement of work.
Disposable heavy duty plastic gloves should be Oxy-acetylene torches may be used for welding
worn at all times, and the affected area washed and cutting, and special care must be taken to
down using wire wool and a limewater (calcium prevent leakage of these gases, with consequent
hydroxide) solution to neutralize the acid before risk of fire and explosion.
disposing of the decomposed Viton residue and The process will produce metal spatter and eye
final cleaning of the area. After use, the plastic and skin protection is necessary.
gloves should be discarded carefully and safely.
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The flame is bright, and eye protection should be
used, but the ultra-violet emission is much less
than that from arc welding, and lighter filters may
be used.
The process itself produces few toxic fumes, but
such fumes and gases may be produced from
coatings on the work, particularly during cutting
away of damaged body parts, and inhalation of the
fumes should be avoided.
In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard TIM0101002
may arise if brazing rods containing cadmium are
used. In this event particular care must be taken 2. Components or assemblies displaying the
to avoid inhalation of fumes and expert advice may warning triangle with the `electrified' arrow and
be required. open book symbol give warning of inherent high
SPECIAL PRECAUTIONS MUST BE TAKEN voltages. Never touch these with the engine
BEFORE ANY WELDING OR CUTTING TAKES running or the ignition switched on. See Electric
PLACE ON VESSELS, WHICH HAVE Shock in this subsection.
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CONTAINED COMBUSTIBLE MATERIALS, FOR
EXAMPLE BOILING OR STEAMING OUT OF
FUEL TANKS.
Warning Symbols on Vehicles

Decals showing warning symbols will be found on
various vehicle components.
These decals must not be removed. The warnings
are for the attention of owners/operators and
persons carrying out service or repair operations TIM0101003
on the vehicle.
3. Vehicles and replacement components which
The most commonly found decals are reproduced contain asbestos are identified by this symbol.
below together with an explanation of the warnings. See Asbestos in this subsection.
TIM0101001 TIM0101004
1. Components or assemblies displaying the 4. Components or assemblies displaying this

caution triangle and open book symbol advise symbol give warning that the component
consultation of the relevant section of the owner contains a corrosive substance. See Acids and
literature before touching or attempting Alkalis in this subsection.
adjustments of any kind.
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TIM0101005
5. Displaying the caution circle with a deleted

lighted match symbol, caution against the use
of naked lights or flames within the immediate
vicinity due to the presence of highly flammable
or explosive liquids or vapors. See Fire in this
subsection.
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TIM0101006
6. Displaying this symbol (normally in conjunction

with 5 above) warn of the presence of potentially
explosive matter within the immediate vicinity.
TIM0101008
7. Displaying this symbol warn that children should

not be allowed in the immediate vicinity
unsupervised.
White Spirit
See Solvents.
2007.50 Transit 11/2006 G17372en

Standard Workshop Practices
Vehicle in Workshop Alternative Fuel — Do's
When working on a vehicle in the workshop always – Do work on the vehicle in a designated area,
make sure that: that is well ventilated and with access restricted
to qualified personnel only.
– the parking brake is applied or the wheels are – Install new warning labels to their original
securely chocked to prevent the vehicle moving locations.
forwards or backwards.
– If possible always isolate the alternative fuel
– the key is removed from key operated hood tank, and run the vehicle on the alternative fuel
locks before any work is carried out around the until it automatically switches to its normal fuel
front of the vehicle. prior to taking the vehicle into the workshop
– if the engine is to be run, there is adequate service area.
ventilation, or an extraction hose to remove – Only use tested and approved components and
exhaust fumes. pipes when repairing or servicing LPG and CNG
– there is adequate room to raise the vehicle and systems.
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remove the wheels, if necessary.
– fender covers are always fitted if any work is to
be carried out in the engine compartment.
Alternative Fuel — Do Nots
– the battery is disconnected if working on the – Do not vent off LPG fuel.
engine, underneath the vehicle, or if the vehicle
– Do not use shop air pressure to force LPG fuel
is raised.
from the fuel tank.
CAUTION:When electric arc welding on a – Do not use paint drying ovens above 40°C for
vehicle, always disconnect the generator any alternative fuel vehicle. LPG and CNG fuel
wiring to prevent the possibility of a surge tanks must be removed from the vehicle prior
of current causing damage to the internal to being put into paint drying ovens above 40°C.
components of the generator.
– Do not modify the system or install new
– if using welding equipment on the vehicle, a components that are not designed for gas
suitable fire extinguisher is readily available. vehicles.
– Do not evacuate fuel tanks unless there is repair
Alternative Fuel that requires the removal of the fuel tank.
– Do not work on the fuel lines or system
WARNING:When servicing the fuel system components unless the alternative fuel has been
always follow the recommended evacuated and the pressure in the system
procedures. Failure to follow these reduced to atmospheric or less.
instructions may result in personal injury. – Do not use anything other than the specified
If the odor of liquefied petroleum gas (LPG) or leak detector fluid to trace fuel leaks.
compressed natural gas (CNG) is present in the Be aware of situations that may cause the LPG or
air in the workshop, warn all persons in the area CNG fuel system to vent off fuel, such as:
to:
– extremely hot days.
– extinguish all flames and lighted tobacco.
– parking by a space heater.
– shut off electrical and air powered equipment.
– hoisting a vehicle up near a ceiling heater.
– evacuate the area.
– ventilate the area. Only fully trained personnel, who are conversant
with local standards, are to work on alternative fuel
– contact the fire control authorities. vehicles.
– remove the vehicle to a dedicated, ventilated
area.
2007.50 Transit 11/2006 G17373en

Towing the Vehicle an instance, the discharged battery must
be recharged immediately after jump
WARNING:When the vehicle is being starting to avoid permanent damage.
towed, the ignition switch must be in – Always make sure that the jumper cables are
position II (steering lock released and adequate for the task. Heavy duty cables must
warning lamps illuminated). Only then will be used.
the steering, turn signal lamps, horn and – Always make sure that the slave battery is of
stop lamps be operational. Failure to follow the same voltage as the vehicle battery. The
these instructions may result in personal batteries must be connected in parallel.
injury.
– Always make sure that switched electric circuits
NOTE:The removable towing eye (if equipped), are switched off before connecting jumper
has a left-hand thread and must be fully tightened cables. This reduces the risk of arcing occurring
before towing can commence. when the final connection is made.
When towing is necessary, the vehicle towing eyes
should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will
not foul the bodywork.
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When a vehicle with automatic transmission is
towed, the gear selector must be in position N
(Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off TIM0103001
the ground.
WARNING:Make sure that the ends of the
Alternatively the vehicle can be transported on a jumper cables do not touch each other or
low loader or a trailer. ground against the vehicle body at any
time while the cables are attached to the
Connecting a Slave Battery Using battery. A fully charged battery, if shorted
Jumper Cables through jumper cables, can discharge at
a rate well above 1000 amps causing
WARNING:If the slave battery has recently violent arcing and very rapid heating of the
been charged and is gassing, cover the jumper cables and terminals, and can even
vent plugs or covers with a damp cloth to cause the battery to explode. Failure to
reduce the risk of explosion should arcing follow these instructions may result in
occur when connecting the jumper cables. personal injury.
Failure to follow these instructions may Always connect the jumper cables in the following
result in personal injury. sequence:
CAUTIONS: – Slave battery positive first and then vehicle

battery positive.
A discharged battery condition may have – Slave battery negative next and then vehicle
been caused by an electrical short circuit. ground at least 12 inches (300 mm) from the
If this condition exists there will be an battery terminal, for example engine lifting eye.
apparently live circuit on the vehicle even
when all normal circuits are switched off. Always reduce the engine speed to idle before
This can cause arcing when the jumper disconnecting the jumper cables.
cables are connected. Before removing the jumper cables from the vehicle
While it is not recommended that the that had the discharged battery, switch on the
vehicle is jump started, it is recognized heater blower (high) or the heated rear window, to
that this may occasionally be the only reduce the voltage peak when the cables are
practical way to mobilize a vehicle. In such removed.
2007.50 Transit 11/2006 G17373en

Always disconnect the jumper cables in the reverse Various solvents are available which are suitable
order to the connecting sequence and do not short for component cleaning. Some components, such
the ends of the cables. as brake hydraulic parts and electrical assemblies
should be cleaned only with recommended solvents
Do not rely on the generator to restore a
— refer to Solvents, Sealers and Adhesives or to
discharged battery. For a generator to recharge a
the section of the manual relevant to the
battery, it would take in excess of eight hours
component.
continuous driving with no additional loads placed
on the battery.
Calibration of Essential Measuring
Component Cleaning Equipment
To prevent the ingress of dirt, accumulations of WARNING:Equipment, which requires

loose dirt and greasy deposits should be removed regular calibration, must be calibrated in
before disconnecting or dismantling components accordance with the manufacturers
or assemblies. instructions. Failure to follow this
instruction may result in personal injury
Components should be thoroughly cleaned before or damage to components.
inspection prior to reassembly.
It is of fundamental importance that certain
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essential equipment, for example torque wrenches,
Cleaning Methods: multimeters, exhaust gas analyzers or rolling roads,
are regularly calibrated in accordance with the
– Dry cleaning. manufacturers instructions.
– Removal of loose dirt with soft or cable brushes.
– Scraping dirt off with a piece of metal or wood.
– Wiping off with a rag.
WARNING:Wear eye protection when
cleaning vehicle components with
compressed air, a steam cleaner or a
power washer. Failure to follow this
instruction may result in personal injury.
CAUTIONS:
Compressed air is sometimes 'wet' so use
with caution, especially on hydraulic
systems.
To prevent damage to the electrical
connectors in the engine compartment, do
not use a steam cleaner or a power washer
to clean the engine compartment.
– Blowing dirt off with compressed air.
– Removal of dry dust using vacuum equipment.
This method must always be used to remove
friction lining material dust (asbestos particles).
– Steam cleaning.
WARNING:Most solvents require careful
handling and some are harmful. Refer to
Health and Safety Precautions and to the
manufacturers literature for the relevant
safety precautions. Failure to follow these
instructions may result in personal injury.
2007.50 Transit 11/2006 G17373en

Solvents, Sealants and Adhesives

Introduction
WARNING:Always handle all solvents,
sealers and adhesives with extreme care.
Some contain chemicals or give off fumes
which can be dangerous to health. Always
follow the manufacturers instructions. If in
doubt about any substance, particularly a
solvent, DO NOT use it.
CAUTION:If in doubt about the suitability
of any proprietary solvent or sealer for a
particular application, contact the
manufacturer of the product for
information regarding storage, handling
and application.
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The Health and Safety Precautions subsection
refers to some commonly used chemicals and
materials, hazards associated with their use, and
safety measures to be taken.
2007.50 Transit 11/2006 G17374en

Road/Roller Testing
Road or roller testing may be carried out for various – that the parking brake is applied.
reasons and a procedure detailing pre-test checks, – that the gear lever is in the neutral position.
engine starting and stopping, pre-driving checks,
– that all instrument gauges (except fuel gauge)
on-test checks and final checks to be completed
read zero.
on completion of the test is given below.
With the ignition switched on, check:
Unless complete vehicle performance is being
checked, the full road test procedure need not be – that the ignition controlled warning lamps are
carried out. Instead, those items particularly illuminated.
relevant to the system(s) being checked can be – that the engine temperature gauge registers a
extracted. reading compatible with the engine temperature.
– that the fuel gauge registers a reading
Pre-Test Checks appropriate to the fuel level in the tank.
– the operation of the parking brake warning lamp
WARNING:If the brake system hydraulic and fluid level warning indicator.
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
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to road test the vehicle until the reason for Road or Roller Testing
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified. CAUTION:If road testing, check the brake
operation while still traveling at low speed
It is suggested that pre-test checks and functional before continuing with the test. If the
tests of those systems and circuits which affect the brakes pull to one side, or appear to be
safe and legal operations of the vehicle, such as otherwise faulty, do not continue with the
brakes, lights and steering, should always be road test until the fault has been found and
carried out before the road or roller test. rectified.
With the ignition switched off, check: During the road or roller test, check:
– the engine oil level. – that the clutch pedal operation is not stiff or
– the engine coolant level. heavy.
– the tires, for correct pressure, compatible types – that the initial gear engagement is smooth and
and tread patterns, and wear within limits. there is no evidence of clutch drag.
– that there is sufficient fuel in the tank to – that the parking brake control operates smoothly
complete the test. and releases quickly and completely.
– all around the engine, transmission and under – that the clutch takes up the drive smoothly,
the vehicle for oil, coolant, hydraulic and fuel without slip or judder.
leaks. Make a note of any apparent leaks and – that gear changing is smooth with no abnormal
wipe off the surrounding areas to make it easier noises or vibrations from the transmission.
to identify the extent of the leak on completion – the engine power output is satisfactory, full
of the test. power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
Starting the Engine speed returns to idle correctly.
– there is no excessive or abnormally colored
NOTE:On initial drive away from cold and within smoke from the engine under normal driving,
the first 1.5 km (1 mile), do not depress the heavy load or overrun conditions.
accelerator pedal beyond half travel until the – that steering operation, including power steering
vehicle has attained a minimum speed of 25 km/h (if equipped), is smooth, accurate, not
(15 miles/h). Never operate at high engine speed excessively heavy or with excessive free play
or with the accelerator pedal at full travel whilst the or vibration.
engine is cold. – that the steering does not pull to one side and
With the ignition switched off, check: self centers smoothly after cornering.
2007.50 Transit 11/2006 G17375en

– that the speedometer, coolant temperature – oil, coolant, hydraulic, air and fuel leaks.
gauge and tachometer (if equipped) register the – abnormal temperature of any moving
correct readings and operate correctly. components or assemblies, for example wheel
– that the switches and controls operate smoothly hubs, transmission and axle, which might
and positively, warning and indicator lamps indicate over tightness or lack of lubrication.
operate correctly and the direction indicator
control self cancels when the steering is
returned to the straight ahead position.
– that the heating and ventilation systems operate
correctly and effectively.
– the brake operation and efficiency.
Brake Testing
WARNING:When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
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instruction may result in personal injury.
For additional information, refer to:Health
and Safety Precautions (100-00 General
Information, Description and Operation).
CAUTIONS:
Avoid brake testing on busy roads where
it may cause inconvenience or danger to
other road users.
Brake testing which includes heavy brake
applications should not be carried out with
new brake pads/discs or linings/drums
until the components have bedded-in. New
brake friction components will not reach
full efficiency until the bedding-in process
is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or
drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature. A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for:
2007.50 Transit 11/2006 G17375en

Battery and Battery Charging Health and Safety Precautions

WARNINGS:
Batteries contain sulphuric acid, avoid
contact with skin, eyes or clothing. Wear
safety goggles when working near the
battery to protect against possible
splashing of the acid solution. In cases of
acid contact with the skin or eyes, flush
immediately with water for a minimum of
15 minutes and seek prompt medical
attention. If swallowed, seek immediate
medical attention.
Batteries normally produce explosive
gases. Do not allow naked flames, sparks
or lighted substances to come near the
battery.
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When charging the battery shield your face
and wear safety goggles. Provide adequate
ventilation.
CAUTION:Boost charging with excessive
current or voltage above 16 volts will
damage the battery.
2007.50 Transit 11/2006 G548994en

Engine Cooling System Health and Safety Precautions

WARNINGS:
Extreme care must be exercised when
handling hot fluids. Always wash off spilled
fluids from exposed skin immediately.
Vapors may be given off from antifreeze
when heated. Avoid breathing these
vapors.
Antifreeze may be absorbed through the
skin in toxic or harmful quantities. If taken
internally, drink water and induce vomiting.
Seek medical attention immediately.
Antifreeze must not be used in any cooling
or industrial water system that is
connected or linked to general water
supplies.
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2007.50 Transit 11/2006 G548995en

Petrol Fuel System Health and Safety Precautions

WARNINGS:
CAUTIONS:
handling hot fluids. Always wash off spilled Fuel injection equipment is manufactured
fluids from exposed skin immediately. to very precise tolerances and fine
clearances. It is essential that absolute
Highly flammable mixtures are always cleanliness is observed when working with
present and may ignite when working on these components.
fuel systems. Do not allow naked flames,
sparks or lighted substances to come near Make sure that the workshop area in which
fuel related components. the vehicle is being worked on is as clean
and as dust free as possible.
There may not be adequate warning of
odor or of irritation before toxic or harmful
effects arise. These may be immediate or
delayed.
Swallowing can result in mouth and throat
irritation and absorption from the stomach
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can result in drowsiness and
unconsciousness. Small amounts can be
fatal to children. Aspiration of liquid into
the lungs, through vomiting, is a very
serious hazard.
Gasoline dries the skin and can cause
irritation and dermatitis on prolonged or
repeated contact. Liquid in the eye causes
severe smarting.
Motor gasoline may contain appreciable
quantities of benzene, which is toxic upon
inhalation, and the concentration of
gasoline vapors must be kept very low.
High concentrations will cause eye, nose
and throat irritation, nausea, headache,
depression and symptoms of drunkenness.
Very high concentrations will result in
rapid loss of consciousness.
Make sure there is adequate ventilation
when handling and using gasoline. Great
care must be taken to avoid the serious
consequences of inhalation in the event of
vapor build up arising from spillages in
confined spaces.
Special procedures apply to cleaning and
maintenance operations on gasoline
storage tanks.
Gasoline should not be used as a cleaning
agent. It must not be siphoned by mouth.
See First Aid.
2007.50 Transit 11/2006 G548996en

Diesel Fuel System Health and Safety Precautions

WARNINGS:
handling hot fluids. Always wash off spilled
fluids from exposed skin immediately.
Combustible.
Gross or prolonged skin contact with high

boiling point gas oils may also cause
serious skin disorders including skin
cancer.
CAUTIONS:
Fuel injection equipment is manufactured
to very precise tolerances and fine
clearances. It is essential that absolute
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cleanliness is observed when working with
these components.
Make sure that the workshop area in which
the vehicle is being worked on is as clean
and as dust free as possible.
NOTE:Soot, discomfort and irritation usually give
adequate warning of hazardous fume
concentrations.
2007.50 Transit 11/2006 G548997en

Air Conditioning (A/C) System Health and Safety Precautions

WARNINGS: Provide adequate ventilation when
Only qualified technicians are allowed to handling refrigerant.
work on air conditioning (A/C) systems. Never release refrigerant into the
Air conditioning (A/C) system components atmosphere.
can become particularly hot or cold. Only use special tools, equipment and
When handling refrigerants, always wear lubricants that are approved for the type
protective goggles and gloves made of of refrigerant being used.
fluoroelastomer. Leather or fabric gloves The pressurized container in the servicing
are not suitable. unit must never be over-filled. The
Make sure that the air conditioning (A/C) refrigerant must have sufficient room to
system is at ambient temperature before expand if the temperature rises.
carrying out any repair. Always follow the manufacturer’s
If liquid refrigerant comes into contact with instructions for the correct servicing unit
the skin, it produces severe frostbite. operating procedure.
cardiagn.com
Immediately rinse the affected areas with
water for 15 minutes. Seek medical CAUTIONS:
attention. Do not mix refrigerant oils for different
If refrigerant comes into contact with the types of refrigerant.
eyes, immediately rinse the eyes with Never mix different types of refrigerant or
plenty of water for 15 minutes. Seek equipment intended for them.
medical attention.
Only use refrigerant in gas form when
If refrigerant comes into contact with naked filling the system through the low-pressure
flames or hot surfaces, it produces toxic connection.
gases (fluorine and phosgene). The toxic
gases formed are readily recognizable by Only use refrigerant in liquid form when
their pungent smell at tiny concentrations. filling the system through the
high-pressure connection.
Refrigerant is flammable and explosive.
Refrigerant attacks certain plastics. Only
Make sure that the local regulations use seals suitable for refrigerant.
regarding work on air conditioning (A/C) If the air conditioning (A/C) compressor is
systems are adhered to. damaged, the fixed orifice tube can
Make sure that refrigerant bottles are not become blocked with metal particles.
exposed to temperatures greater than 45°C. Any sort of blockage in the refrigerant
Make sure that refrigerant bottles are circuit will damage the air conditioning
closed properly. (A/C) compressor irreparably.
Toxic gases generated when refrigerant is If the air conditioning (A/C) system has
heated are hazardous to health. The gases been opened for a period greater than 2
have an irritating smell and can cause lung hours, a new receiver drier must be
damage. The symptoms can continue for installed and the evacuating time to be
a long time after having been in contact increased by a minimum of 2 hours.
with the gases. The gases can cause lung NOTE:New air conditioning (A/C) compressors are
damage even if the amount of gas in the delivered prefilled.
air is too small to smell.
NOTE:Refrigerant oil in new air conditioning (A/C)
Gaseous refrigerant has a higher density compressors can contain Teflon, visible as white
than air. There is a danger of suffocation particles, which will not harm the system.
when working close to the ground or in
workshop pits.
2007.50 Transit 11/2006 G548993en

Supplemental Restraint System (SRS) Health and Safety

Precautions
WARNINGS:
Undeployed pyrotechnic supplemental
restraint system (SRS) components must
not be deployed in the vehicle.
Never carry out any electrical measurement
on disconnected, undeployed
supplemental restraint system (SRS)
pyrotechnic components.
Pyrotechnic components must not be
disassembled.
Pyrotechnic components are not
interchangeable between vehicles.
Always carry a live air bag module away
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from the body with the air bag or trim cover
pointing upwards.
Live air bag modules must be placed in a
suitable cage when removed from the
vehicle. The air bag or trim cover must be
facing upwards.
CAUTIONS:
Supplemental restraint system (SRS)
components must not be subjected to
temperatures higher than 110°C.
Never install aftermarket accessories to
the vehicle on or adjacent to the
supplemental restraint system (SRS)
module.
2007.50 Transit 11/2006 G548998en

Brake System Health and Safety Precautions

WARNING:Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after
handling. If brake fluid comes into contact
with the eyes, flush the eyes with cold
running water for 15 minutes. Seek medical
attention if irritation persists. If taken
internally, drink water and induce vomiting.
Seek medical attention immediately.
CAUTION:If brake fluid is spilled on the
paintwork, the affected area must be
immediately washed down with cold water.
cardiagn.com
2007.50 Transit 11/2006 G565862en

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100-00-1 General Information 100-00-1

SECTION 100-00 General Information

DESCRIPTION AND OPERATION

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About This Manual

Warnings, Cautions and Notes in This

Item Designation Description

2007.50 Transit 11/2006 G935689en

ebay cheap car manuals uk

Item Designation Description

2007.50 Transit 11/2006 G935689en

ebay cheap car manuals uk

Health and Safety symbols recommend the use of

2007.50 Transit 11/2006 G935689en

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Warning symbols are used to indicate potential

2007.50 Transit 11/2006 G935689en

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Location symbols are used to show the location of

2007.50 Transit 11/2006 G935689en

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Gearshift lever or selector lever position symbols

2007.50 Transit 11/2006 G935689en

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2007.50 Transit 11/2006 G935689en

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Movement arrows are used to show three

2007.50 Transit 11/2006 G935689en

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The following graphic illustrates a set of symbols

2007.50 Transit 11/2006 G935689en

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Measurement symbols provide detailed information

2007.50 Transit 11/2006 G935689en

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Special Tools and Torque Figure(s) If components need to be removed or

2007.50 Transit 11/2006 G935689en

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2007.50 Transit 11/2006 G935689en

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Health and Safety Precautions

2007.50 Transit 11/2006 G17372en

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Mixing should be carried out in well ventilated

Many are irritant, sensitizing or harmful to the skin

Follow manufacturers instructions.

2007.50 Transit 11/2006 G17372en

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2007.50 Transit 11/2006 G17372en

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2007.50 Transit 11/2006 G17372en

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Dusts Exhaust Fumes

Electric Shock There may not be adequate warning of odor or of

2007.50 Transit 11/2006 G17372en

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2007.50 Transit 11/2006 G17372en

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